Panel systems and methods of assembling panel systems

ABSTRACT

A panel system includes a tab panel having at least one tab extending therefrom. The tab panel has a core and a facesheet adjacent the core. The panel system includes a slot panel having at least one slot receiving the corresponding tab of the tab panel therein. The slot panel has a core and a facesheet adjacent the core. The slot is formed in the facesheet and at least a portion of the core. The panel system includes a clip positioned between the tab panel and the slot panel. The clip is at least partially received in the slot. The clip has a tab panel securing member being secured to the tab panel and the clip has a slot panel securing member being secured to the slot panel. The clip securely joins the tab panel to the slot panel.

BACKGROUND

The present disclosure relates generally to panel systems and methods ofassembling panel systems, such as panel systems used in aircraft.

Panel systems, such as those used in aircraft, use composite panelstructures in forming galleys, lavatories, partitions, stow bins,closets, crew rests, and the like. The panels of the panel systems maybe joined together using tab-and-slot joints or mortise-and-tenonjoints. For example, one of the panels may have slots formed therein,while the other panel may have tabs extending therefrom that arereceived in corresponding slots. However, during the manufacture of thepanel systems, such known tab and slot joints typically require the useof adhesive to permanently join the panels together. For example, theslots are filled with adhesive and the tabs are set in the depositedglue. Alternatively, a small hole is provided adjacent each slot and,after the tabs are inserted into the slots, adhesive is injected intothe hole to fill the slot and secure the tab in the slot.

Existing assembly methods for panel systems are not withoutdisadvantages. For instance, excess adhesive tends to flow out of theslot. The technician cleans the excess adhesive by either wiping theadhesive before curing or by sanding off the adhesive after curing. Theinstallation, use, and removal of such adhesive may increase labor,materials, and tooling costs, which, in turn, may increase overallproduction costs. In addition, the installation, use, and removal ofsuch adhesive may increase the time to assemble the panel structures,which, in turn, may increase the overall production costs. For example,the panels may need to be clamped together for the entire curing time ofthe adhesive, which may be hours.

Another problem associated with the use of the adhesive in the slots tohold the tabs occurs after curing. The adhesive tends to pull theopposite facesheet of the panel inward (e.g., toward the tab) andcreates an indentation in the finished surface of the panel. Suchindentation is typically filled with putty or other filler and sanded toprovide a smooth, finished surface. Repairing the indentation mayincrease labor, materials, and tooling costs, which, in turn, mayincrease overall production costs. In addition, repairing theindentation may increase the time to assemble the panel structures,which, in turn, may increase the overall production costs.

SUMMARY

In accordance with one embodiment, a panel system is provided includinga tab panel having at least one tab extending therefrom. The tab panelhas a core and a facesheet adjacent the core. The panel system includesa slot panel having at least one slot receiving the corresponding tab ofthe tab panel therein. The slot panel has a core and a facesheetadjacent the core. The slot is formed in the facesheet and at least aportion of the core. The panel system includes a clip positioned betweenthe tab panel and the slot panel. The clip is at least partiallyreceived in the slot. The clip has a tab panel securing member beingsecured to the tab panel and the clip has a slot panel securing memberbeing secured to the slot panel. The clip securely joins the tab panelto the slot panel.

In accordance with a further embodiment, a panel system kit is providedincluding a plurality of panels each having a core between oppositefacesheets where each of the panels is configured to have at least oneof a slot or a tab. The panel system kit includes a plurality of clipsconfigured to be positioned between corresponding panels to join thepanels. Each clip has a slot panel securing member configured tosecurely engage a corresponding facesheet of the panel having the slotand each clip has a tab panel securing member configured to securelyengage a corresponding facesheet of the panel having the tab.

In accordance with a further embodiment, a method of assembling a panelsystem is provided. The panel system includes a tab panel having atleast one tab extending therefrom and a slot panel having at least oneslot receiving the corresponding tab of the tab panel, where the tabpanel and slot panel each having a core and a facesheet adjacent thecore. The panel system further includes a clip having a tab panelsecuring member and a slot panel securing member. The method includesinserting the clip onto the tab panel adjacent the tab or the slot paneladjacent the slot, inserting the tab in the slot such that the clip ispositioned between a portion of the tab panel and a portion of the slotpanel, and inserting the slot panel securing member between thefacesheet of the slot panel and the core of the slot panel.

The features and functions that have been discussed can be achievedindependently in various embodiments or may be combined in yet otherembodiments, further details of which can be seen with reference to thefollowing description and drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an aircraft that may incorporate one ormore exemplary embodiments of a panel system formed in accordance withan exemplary embodiment.

FIG. 2 is a perspective view of the panel system in accordance with anexemplary embodiment.

FIG. 3 illustrates a portion of the panel system showing variouscomponents of the panel system in an unassembled state.

FIG. 4 is a perspective view of a portion of the panel system duringassembly.

FIG. 5 illustrates a portion of the panel system showing a tab paneljoined to a slot panel of the panel system.

FIG. 6 is a cross-sectional view of the panel system in an assembledstate.

FIG. 7 is a side view of a clip of the panel system formed in accordancewith an exemplary embodiment.

FIG. 8 is a perspective view of a clip of the panel system formed inaccordance with an exemplary embodiment.

FIG. 9 is a front perspective view of a clip of the panel system formedin accordance with an exemplary embodiment.

FIG. 10 is a rear perspective view of the clip shown in FIG. 9.

FIG. 11 illustrates the clip shown in FIG. 9 coupled to the tab panel.

FIG. 12 is a cross-section view of the panel system using the clipsshown in FIG. 9 to secure the tab panel to the slot panel.

DETAILED DESCRIPTION

The following detailed description of certain embodiments will be betterunderstood when read in conjunction with the appended drawings. Itshould be understood that the various embodiments are not limited to thearrangements and instrumentality shown in the drawings.

As used herein, an element or step recited in the singular and proceededwith the word “a” or “an” should be understood as not excluding pluralof said elements or steps, unless such exclusion is explicitly stated.Furthermore, references to “an embodiment” or “one embodiment” are notintended to be interpreted as excluding the existence of additionalembodiments that also incorporate the recited features. Moreover, unlessexplicitly stated to the contrary, embodiments “comprising” or “having”an element or a plurality of elements having a particular property mayinclude additional such elements not having that property.

The embodiments described herein include improved joints for panelsystems and methods of fabricating such panel systems that provideadvantages over known systems and methods. For example, the hereindescribed embodiments may reduce or eliminate excess adhesive and/or mayeliminate surface indentations. Described herein are various embodimentsof a panel system and a method of assembling a panel system. The panelsystem includes a tab panel having at least one tab extending therefromand a slot panel having at least one slot receiving the correspondingtab of the tab panel therein. The panels each have a core and afacesheet adjacent the core. Various embodiments of the panel systeminclude a clip positioned between the tab panel and the slot panel withthe clip is at least partially received in the slot. The clip has a tabpanel securing member secured to the tab panel and a slot panel securingmember secured to the slot panel. The clip securely joins the tab panelto the slot panel. The panel system may be assembled by inserting theclip onto the tab panel adjacent the tab or the slot panel adjacent theslot, inserting the tab in the slot such that the clip is positionedbetween a portion of the tab panel and a portion of the slot panel, andinserting the slot panel securing member between the facesheet of theslot panel and the core of the slot panel.

FIG. 1 is perspective view of an aircraft 10 that may incorporate one ormore exemplary embodiments of a panel system 100 formed in accordancewith an exemplary embodiment. The aircraft 10 includes a fuselage 12, anose 14, a cockpit 16, wings 18, one or more propulsion units 20, avertical tail portion 22, and horizontal tail portions 24. Although theaircraft 10 is generally representative of a commercial passengeraircraft having one or more structures 26 that incorporate the panelsystem 100, such as a monument, a galley, a lavatory, partition, stowbins, closets, crew rests, and the like, the teachings of the disclosedembodiments may be applied to other passenger aircrafts, cargo aircraft,military aircraft, rotorcraft, and other types of aircraft or aerialvehicles, as well as aerospace vehicles, satellites, space launchvehicles, rockets, and other aerospace vehicles, as well as boats andother watercraft, trains, automobiles, trucks, buses, or other suitablestructures having one or more structures 26 made with one or moreembodiments of the panel system 100.

FIG. 2 is a perspective view of the panel system 100 in accordance withan exemplary embodiment. The panel system 100 includes a plurality ofpanels 102 that are joined at one or more joints 104. In an exemplaryembodiment, the joints 104 are a tab-and-slot arrangement, also referredto as a tenon-and-mortise arrangement. The joints 104 each include clips106 to hold the panels 102 together. The clips 106 may be self-lockingto the panels 102, such that the clips 106 do not require additionalfasteners or adhesives to secure the panels 102 together. For example,the clips 106 may snapably engage adjacent panels 102 to hold the panelstogether. The clips 106 and one or more of the panels 102 may bepackaged as a kit and sold to a manufacturer of panel systems. Thepanels 102 may be sold in pre-formed states, such as with tabs and slotsformed therein, or alternatively, the panel system manufacturer may formthe tabs and slots in the panels 102 during manufacture. Alternatively,the panels may be sold preformed with the clips 106 already installedand ready for assembly. In other embodiments, the pre-assembled panelsystems 100 may be sold to an installer or manufacturer of the aircraft.

Each panel 102 may be a sandwich composite panel designed to belightweight and meet FFA material requirements, such as flammabilityrequirements. Each panel 102 includes two opposite facesheets 110, 112having a core 114 sandwiched therebetween. The facesheets 110, 112, alsoknown as skins, may be made of a fiberglass resin, a graphite resin, apara-aramid synthetic fiber resin, a prepreg composite material, oranother suitable composite material and may be formed by laying up thematerials in a known layup and/or cure process. The facesheets 110, 112may also be formed of a lightweight metal material, such as aluminum, ora combination of a metal and composite material in alternativeembodiments. The core 114 may be a honeycomb core that is lightweightand high-strength. The core 114 may include a foam material such as opencell foam, a polymeric, cellular solid foam, a melamine foam, a closedcell foam, or another suitable foam material. The core 114 may be formedfrom other materials, such as a meta-aramid material, a resinimpregnated paper material, a light-weight metal material, such asaluminum, a combination of metal and composite material, and the like inalternative embodiments.

The panels 102 may be joined at ends or edges of the panels 102, oralternatively may be joined at mid-portions of the panels 102. Thepanels 102 may have any shape depending on the particular application,and are not limited to the rectangular shapes illustrated in FIG. 2.Optionally, a single panel 102 may be joined to multiple other panels102. Some panels 102 may define inner panels, some panels 102 may defineouter panels, and some panels 102 may define both inner and outer panelsof the panel system 100. The joints 104 may be provided at any intervalalong the panels 102. For example, the joints 104 may be provided at ornear the ends or edges of the panels 102, at any mid-portion between thepanels 102, and at any spacing from each other.

FIG. 3 illustrates a portion of the panel system 100 showing variouscomponents of the panel system 100 in an unassembled state. FIG. 3 showsan exemplary embodiment of one of the clips 106 used to hold the panels102 together. In the illustrated embodiment, a first panel 120 isprovided with a slot 122 formed therein. Such panel, including the slot122, may be referred to as a slot panel 120 hereinafter. FIG. 3illustrates a second panel 124 with a tab 126 extending therefrom. Suchpanel, including the tab 126, may be referred to as a tab panel 124hereinafter. The slot panel 120 may include any number of slots 122 andthe tab panel 124 may include any number of tabs 126. In someembodiments, either or both of the panels 102 may include both slots 122and tabs 126 for connecting to each other and/or for connecting to otherpanels 102.

The slot 122 may be formed by milling the slot panel 120 to form theslot 122. For example, the slot 122 may be milled using a computernumeric control (CNC) machine or other machine. The slot 122 is formedthrough the first facesheet 110 and at least part way through the core114. A portion of the core 114 is exposed in the slot 122. The slot 122may extend through the second facesheet 112 in various embodiments. Theslot 122 is sized and shaped to receive the tab 126 and the clip 106. Inthe illustrated embodiment, the slot 122 is generally rectangular;however other shape slots may be used in alternative embodiments. Theslot 122 may be provided at or near an edge of the slot panel 120, oralternatively the slot 122 may be provided along an interior portion ofthe slot panel 120 remote from the edge thereof.

The tab 126 extends from an edge 128 of a main body 132 of the tab panel124. The tab 126 may be formed by milling the edge 128, such as using aCNC machine or another type of machine. The tabs 126 may extend theentire thickness of the tab panel 124 and include both facesheets 110,112 and the core 114. Optionally, the edge 128 and end edge 134 mayinclude a facesheet covering the core 114. Alternatively, the core 114may be exposed at the edge 128 and end edge 134. The tab 126 extends toan end edge 134 away from the main body 132. The tab 126 has a width 130defined between the main body 132 of the tab panel 124 and the end edge134. The width 130 may be less than a thickness or depth of the slotpanel 120 allowing the tab 126 to be received in the slot 122 such thatthe main body 132 rests generally flush with the facesheet 110 of theslot panel 120.

In an exemplary embodiment, the tab panel 124 includes one or morechannels 136 formed in the facesheet 110 and for the facesheet 112 ofthe tab panel 124. The channels 136 are configured to receive portionsof the clip 106 when assembled. In the illustrated embodiment, thechannels 136 may be long, narrow slits milled into the facesheets 110,112. The channels 136 are positioned a distance away from the end edge134 of the tab 126 in the illustrated embodiment. The channels 136 areprovided in the main body 132, however the channels 136 may be providedin the tab 126 in alternative embodiments. Optionally, each facesheet110, 112 may include multiple channels 136 associated with each tab 126for receiving different portions of the clips 106.

The clip 106 is configured to be securely coupled to the slot panel 120and the tab panel 124 to securely join the tab panel 124 to the slotpanel 120. The clip 106 may be self-locking to the slot panel 120 and/ortab panel 124. For example, the clip 106 may be secured to the slotpanel 120 without additional fasteners or adhesives. Similarly, the clip106 may be secured to the tab panel 124 without the use of additionalfasteners or adhesives. The clip 106 may snapably engage the slot panel120 and/or tab panel 124 during assembly. Such self-locking and/orsnapable engagement allows for quick installation and assembly of thepanel system 100. However, in other various embodiments, the clip 106may be secured to the slot panel 120 and/or tab panel 124 using adhesiveto enhance the mechanical integrity therebetween. For example, the clip106 may be secured in the slot 122 using adhesive as either a primary orsecondary mechanical securing connection thereto.

The clip 106 includes one or more slot panel securing members 140 andone or more tab panel securing members 142. The slot panel securingmembers 140 secure the clip 106 to the slot panel 120. The tab panelsecuring members 142 secure the clip 106 to the tab panel 124. In theillustrated embodiment, the slot panel securing members 140 are flangesor protrusions extending outward from the clip 106. Such slot panelsecuring members 140 are configured to engage the facesheet 110 of theslot panel 120 when the clip 106 is loaded into the slot 122. In theillustrate embodiment, the tab panel securing members 142 are flanges orprotrusions extending inward. The tab panel securing members 142 areconfigured to be received in corresponding channels 136 in thefacesheets 110, 112 of the tab panel 124 to securely join the clip 106to the tab panel 124.

The clip 106 may be manufactured from metal, plastic, or othermaterials. The clip 106 is U-shaped; however other shapes are possiblein alternative embodiments. In the illustrated embodiment, the clip 106includes a base portion 150 and a pair of legs 152, 154 extending fromopposite sides of the base portion 150. The slot panel securing members140 extend from the base portion 150. The tab panel securing members 142extend from the legs 152, 154. The base portion 150 is defined by an endwall 156 and opposite side walls 158, 160. The side walls 158, 160extend from opposite sides of the end wall 156. The leg 152 extends fromthe side wall 158, and the leg 154 extends from the side wall 160. Thebase portion 150 defines a pocket 162 between the side walls 158, 160.The pocket 162 is configured to receive at least a portion of the tab126 when the tab panel 124 is coupled to the slot panel 120.

In an exemplary embodiment, the base portion 150 is generally theportion of the clip 106 that is received in the slot 122. The slot panelsecuring members 140 extend outward from the side walls 158, 160, awayfrom the pocket 162, to engage the interior surface of the facesheet110. The slot panel securing members 140 are configured to be positionedbetween the facesheet 110 and the core 114.

In an exemplary embodiment, the legs 152, 154 extend beyond the sidewalls 158, 160 and are generally the portions of the clip 106 exteriorof the slot 122. The legs 152, 154 are configured to extend along themain body 132 of the tab panel 124. The legs 152, 154 extend beyond thetab 126 along the facesheets 110, 112 of the tab panel 124 to thechannels 136. The tab panel securing members extend inward into a space164 defined between the legs 152, 154. When assembled, the tab panel 124is positioned in the space 164 and the tab panel securing members 142extend into the tab panel 124 through the channels 136.

In an exemplary embodiment, the side walls 158, 160 and/or the legs 152,154 are inwardly tapered. Such inward taper ensures that the clip 106presses against the tab panel 124 such that the tab panel securingmembers 142 enter into the channels 136 to engage the tab panel 124.Optionally, when the tab panel 124 in coupled to the slot panel 120 suchthat the tab 126 is loaded into the pocket 162 and slot 122, the tab 126presses outward against the sidewalls 158, 160 to ensure that the slotpanel securing members 140 are positioned and aligned behind thefacesheet 110 of the slot panel 120 and cannot slip through the slot122.

FIG. 4 is a perspective view of a portion of the panel system 100 duringassembly. During assembly, the clip 106 is loaded into the slot 122. Thebase portion 150 is received in the slot 122 behind an interior surface170 of the facesheet 110. The legs 152, 154 extend forward of the baseportion 150 beyond an exterior surface 172 of the facesheet 110. Theclip 106 is open and able to receive a portion of the tab panel 124therein. For example, the tab 126 is loaded through the space 164between the legs 152, 154 and into the pocket 162. A portion of the mainbody 132 of the tab panel 124 is configured to be received in the space164 between the legs 152, 154. The tab panel 124 is loaded into the clip106 until the clip 106 is securely joined to the tab panel 124. Forexample, the tab panel 124 is loaded into the clip 106 until the tabpanel securing members 142 are received in the corresponding channels136 in the facesheets 110, 112 of the tab panel 124. The tab panelsecuring members 142 clip into the facesheets 110, 112 of the tab panel124 to securely join the tab panel 124 to the slot panel 120.Optionally, the tab panel securing members 142 may snapably engage thetab panel 124 when the tab panel securing members 142 are aligned withthe channels 136.

FIG. 5 illustrates a portion of the panel system 100 showing the tabpanel 124 joined to the slot panel 120. FIG. 6 is a cross-sectional viewof the panel system 100 in an assembled state. The clip 106 securelyjoins the tab panel 124 to the slot panel 120. The tab panel securingmembers 142 clip into the channels 136 in the facesheets 110, 112 of thetab panel 124 to hold the tab panel 124 relative to the slot panel 120.The legs 152, 154 extend along both sides of the tab panel 124 to thecorresponding channels 136.

When assembled, as shown in FIG. 6, the slot panel securing members 140are captured behind the interior surface 170 of the facesheet 110 of theslot panel 120. The tab panel 124 forces the sidewalls 158, 160 outwardensuring that the slot panel securing members 140 remain locked behindthe facesheet 110. The slot panel 120 has an edge 174 around a perimeterof the slot 122. The slot panel securing members 140 are secured againstthe interior surface 170 adjacent the edge 174. The slot panel securingmembers 140 are located between the facesheet 110 and portions of thecore 114. For example, the core 114 may be at least partially milled outbehind the facesheet 110. Alternatively, the slot panel securing members140 may displace a portion of the core 114 when the clip 106 is loadedinto the slot 122.

FIG. 7 is a side view of a clip 200 formed in accordance with anexemplary embodiment. The clip 200 is similar to the clip 106; however,the clip 200 includes a single leg as opposed to the pair of legs 152,154 of the clip 106. The clip 200 includes a base portion 202 havingsidewalls 204, 206. The clip 200 includes a leg 208 extending from thesidewall 204. The clip 200 includes slot panel securing members 210extending from the sidewalls 204, 206 and a tab panel securing member212 extending inward from the leg 208. The single-leg clip 200 issimilar to the double-leg clip 106, except one of the legs 152 or 154 isomitted in the single-leg clip 200. Accordingly, at least some of thedescription related to the clip 106 is applicable to the clip 200. Byhaving a single leg 208 as opposed to a pair of legs, the clip 200 inonly visible on one side of the tab panel 124 (shown in FIG. 3). Theclip 200 may be better hidden and less visible than the clip 106. Forexample, the clip 200 may be oriented such that the visible leg 208 isprovided on a side of the tab panel 124 that is covered, unexposed, orotherwise less visible in the passenger compartment of the aircraft.

FIG. 8 is a perspective view of a clip 300 formed in accordance with anexemplary embodiment. The clip 300 is similar to the clips 106, 200;however, the legless clip 300 does not include any legs visible alongthe corresponding tab panel 124 (shown in FIG. 3). The legless clip 300is similar to the double-leg clip 106 or the single leg clip 200, exceptboth of the legs 152 or 154 are omitted in the legless clip 300.Accordingly, at least some of the description related to the clip 106and/or the clip 200 is applicable to the clip 300. The clip 300 isdesigned to be entirely contained within the slot 122 of the slot panel120. In other words, the clip 300 is contained entirely behind thefacesheet 110 of the slot panel 120.

The clip 300 includes a base portion 302 having sidewalls 304, 306. Thesidewalls 304, 306 may be considerably shorter than the sidewalls of theclip 106. The clip 300 may have a series of interspersed slot panel arms310 and tab panel legs 312. The slot panel arms 310 and tab panel legs312 are independently moveable relative to each other. The sidewalls304, 306 and/or the slot panel arms 310 and tab panel legs 312 define apocket 308 configured to receive the tab 126 of the tab panel 124.

The slot panel arms 310 have corresponding slot panel securing members314 extending therefrom. The tab panel legs 312 have corresponding tabpanel securing members 316 extending therefrom. The slot panel arms 310and/or the slot panel securing members 314 may be angled outward andextend to distal ends 318. The slot panel securing members 314 may bedefined at the distal ends 318, which may engage or abut the interiorsurface of the facesheet 110 of the slot panel 120 when assembled. Forexample, the distal ends 318 may be angled away from the pocket 308 suchthat the slot panel securing members may be aligned behind the facesheet110 of the slot panel 120.

The tab panel securing members 316 may be flanges angled inward from thetab panel legs 312. The tab panel securing members 316 are configured tobe received in corresponding channels 136 formed in the tab panel 124.For example, the channels 136 may be provided in the tab 126 such that,when the tab 126 is loaded into the pocket 308, the tab panel securingmembers 316 are received in the channels 136 of the tab 126 to securethe tab panel 124 to the slot panel 120. Neither the slot panel arms 310nor the tab panel legs 312 extend out of the slot 122 such that noportion of the clip 300 is visible after assembly.

In an exemplary embodiment, the slot panel arms 310 and tab panel legs312 may be independently deflectable relative to each other. Any numberof slot panel arms 310 and tab panel legs 312 may be provided along eachof the sidewalk 304, 306. In the illustrate embodiment, five slot panelarms 310 and four tab panel legs 312 extend from each of the sidewalls304, 306; however, any number of slot panel arms 310 and tab panel legs312 may be provided in alternative embodiments.

FIG. 9 is a front perspective view of a clip 400 formed in accordancewith an exemplary embodiment. FIG. 10 is a rear perspective view of theclip 400. The clip 400 is similar to the clip 106, except the clip 400is configured to be initially coupled to the tab panel 124 rather thanthe slot panel 120 (both shown in FIG. 3). For example, the clip 400includes both tab panel securing members and slot panel securing memberseither or both of which may snapably couple to the corresponding panels.Accordingly, at least some of the description related to the clip 106 isapplicable to the clip 400.

The clip 400 includes a base portion 402. A slot panel securing member404 extends from the base portion 402 and is configured to engage andsecurely couple to the slot panel 120. A tab panel securing member 406extends from the base portion 402 and is configured to engage andsecurely couple to the tab panel 124.

In an exemplary embodiment, the base portion 402 is a plate. In theillustrated embodiment, the base portion 402 is an oval shaped plate;however, other shapes are possible in alternative embodiments. The tabpanel securing member 406 extends rearward from the base portion 402. Inthe illustrated embodiment, the tab panel securing mechanism 406 is aprotrusion that is generally oval shaped configured to be received in anoval shaped channel formed in the tab panel. Other shapes are possiblein alternative embodiments. The tab panel securing mechanism 406includes a cutout in a portion thereof generally aligned with the slotpanel securing member 404.

In the illustrated embodiment, the slot panel securing mechanism 404includes a deflectable tab 410 hingedly coupled to the base portion 402.The deflectable tab 410 may be deflected into the cutout 408 and may bedeflected outward from the base portion 402. In an exemplary embodiment,the deflectable tab 410 is angled forward or outward from the baseportion 402. The slot panel securing member 404 includes a flange 412 ata distal end of the deflectable tab 410. The flange 412 in configured toengage the slot panel 120 to retain the clip 400 in the slot panel 120.

FIG. 11 illustrates the clip 400 coupled to the tab panel 124. In anexemplary embodiment, clips 400 are provided on both side of the tabpanel 124. The clip 400 is coupled to the tab panel 124 such that thebase portion 402 abuts against the exterior surface 172 of the facesheet110 of the tab panel 124. The tab panel 124 includes a channel 430 thatreceives the clip 400. The channel 430 is provided in the tab 126. Thechannel 430 is located such that the slot panel securing member 404 isconfigured to be located below the facesheet 110 of the slot panel 120when the tab panel 124 is coupled to the slot panel 120. The tab panelsecuring mechanism 406 (shown in FIG. 10) is received in the channel 430and secured therein. Optionally, the clip 400 may be secured in thechannel 430 using adhesive or a friction fit. Alternatively, the tabpanel securing member 406 may include a flange or other protrusion thatis configured to be captured behind the facesheet 110 of the tab panel124. When the clip 400 is coupled to the tab panel 124, the slot panelsecuring mechanism 404 is angled outward from the base portion 402. Theflange 412 is outward of, or forward of, the exterior surface 172 of thefacesheet 110 of the tab panel 124.

FIG. 12 is a cross-section view of a panel system 450 using the clips400 to secure the tab panel 124 to the slot panel 120. The clips 400 areprovided on both sides of the tab panel 124. The slot panel securingmembers 404 are flared outward and are configured to be captured behindthe interior surface 170 of the facesheet 110 of the slot panel 120. Theslot panel securing members 404 are positioned between the facesheet 110and the core 114.

In an exemplary embodiment, the slot panel securing members 404 aredeflectable. For example, the deflectable tabs 410 may be deflectedinward by the facesheet 110 of the slot panel 120 when the tab 126 ofthe tab panel 124 is loaded into the slot 122. After the tab panel 124is fully mated with the slot panel 120, the slot panel securing members404 are configured to engage and secure to the slot panel 120. In anexemplary embodiment, the deflectable tabs 410 are deflectable betweenan unlatched position and a latched position. The deflectable tabs 410are deflected to the unlatched position as the clip 400 is loaded intothe slot 122 of the slot panel 120. For example, the facesheet 110 maycause the deflectable tabs 410 to deflect inward to the unlatchedposition. The deflectable tabs 410 are deflected outward to the latchedposition after the deflectable tabs 410 clear the facesheet 110 of theslot panel 120. In the latched position, the flanges 412 engage theinterior surface 170 of the facesheet 110 of the slot panel 120 tosecure the clip 400 in the slot 120. In an exemplary embodiment, thedeflectable tabs 410 are elastically deflected from the latched positionto the unlatched position as the clips 400 are loaded into the slot 122.Once the facesheet 110 no longer presses the deflectable tabs inward,the deflectable tabs 410 return to the normal, latched position tosecurely join the tab panel 124 to the slot panel 120.

It is to be understood that the above description is intended to beillustrative, and not restrictive. For example, the above-describedembodiments (and/or aspects thereof) may be used in combination witheach other. In addition, many modifications may be made to adapt aparticular situation or material to the teachings of the variousembodiments without departing from the scope thereof. Dimensions, typesof materials, orientations of the various components, and the number andpositions of the various components described herein are intended todefine parameters of certain embodiments, and are by no means limitingand are merely exemplary embodiments. Many other embodiments andmodifications within the spirit and scope of the claims will be apparentto those of skill in the art upon reviewing the above description. Thescope of the various embodiments should, therefore, be determined withreference to the appended claims, along with the full scope ofequivalents to which such claims are entitled. In the appended claims,the terms “including” and “in which” are used as the plain-Englishequivalents of the respective terms “comprising” and “wherein.”Moreover, in the following claims, the terms “first,” “second,” and“third,” etc. are used merely as labels, and are not intended to imposenumerical requirements on their objects. Further, the limitations of thefollowing claims are not written in means-plus-function format and arenot intended to be interpreted based on 35 U.S.C. §112(f), unless anduntil such claim limitations expressly use the phrase “means for”followed by a statement of function void of further structure.

What is claimed is:
 1. A panel system comprising: a tab panel having atleast one tab extending therefrom, the tab panel having a core and afacesheet adjacent the core, the tab of the tab panel having a channelin the facesheet and the core: a slot panel having at least one slot forreceiving the corresponding tab of the tab panel therein, the slot panelhaving a core and a facesheet adjacent the core, the slot formed in thefacesheet and at least a portion of the core; a clip configured to bepositioned between the tab panel and the slot panel, the clip beingsecured in the channel of the tab prior to loading the tab into theslot, the clip being at least partially received in the slot, the cliphaving a tab panel securing member being secured to the tab panel, theclip having a slot panel securing member being secured to an interiorsurface of the slot panel, wherein the facesheet of the slot panel hasan edge around a perimeter of the slot, the slot panel includes aninterior surface and an exterior surface, the slot panel securing memberis secured against the interior surface adjacent the edge; the clipsecurely joining the tab panel to the slot panel.
 2. The panel system ofclaim 1, wherein the slot panel securing member snapably engages theslot panel to securely join the clip to the slot panel.
 3. The panelsystem of claim 1, wherein the slot panel securing member is positionedbetween the facesheet and the core of the slot panel.
 4. The panelsystem of claim 1, wherein the slot panel securing member comprises aflange extending into the slot behind the facesheet, the facesheetcapturing the flange of the clip in the slot.
 5. The panel system ofclaim 1, wherein the clip comprises a base portion, the channel in thetab of the tab panel being a preformed channel in the tab, the tab panelsecuring member comprising a protrusion extending from the base portionand received in the preformed channel, the slot panel securing membercomprising a deflectable tab extending from the base portion deflectablebetween an unlatched position and a latched position, the deflectabletab being deflected to the unlatched position as the clip is loaded intothe slot, the deflectable tab being deflected to the latched positionafter the deflectable tab clears the facesheet of the slot panel, thedeflectable tab engaging an interior surface of the facesheet of theslot panel in the latched position.
 6. The panel system of claim 1,wherein the clip is secured to the core of the slot panel usingadhesive.
 7. The panel system of claim 1, wherein the channel ispositioned a distance away from an end edge of the tab.
 8. The panelsystem of claim 1, wherein the clip is contained behind an exteriorsurface of the facesheet of the slot panel.
 9. The panel system of claim1, wherein the core of the tab panel is a honeycomb core having ahoneycomb structure and wherein the core of the slot panel is ahoneycomb core having a honeycomb structure.
 10. The panel system ofclaim 1, wherein the core of the tab panel is a foam material andwherein the core of the slot panel is a foam material.
 11. A panelsystem comprising: a tab panel having at least one tab extendingtherefrom, the tab panel having a core and a facesheet adjacent thecore; a slot panel having at least one slot for receiving thecorresponding tab of the tab panel therein, the slot panel having a coreand a facesheet adjacent the core, the slot formed in the facesheet andat least a portion of the core; and a clip configured to be positionedbetween the tab panel and the slot panel, the clip being at leastpartially received in the slot, the clip having a tab panel securingmember being secured to the tab panel, the clip having a slot panelsecuring member being secured to an interior surface of the slot panel,the clip securely joining the tab panel to the slot panel; wherein thetab panel includes at least one slot and the slot panel includes atleast one tab with a corresponding clip therebetween.
 12. The panelsystem of claim 11, wherein the slot panel securing member snapablyengages the slot panel to securely join the clip to the slot panel. 13.The panel system of claim 11, wherein the slot panel securing member ispositioned between the facesheet and the core of the slot panel.
 14. Thepanel system of claim 11, wherein the slot panel securing membercomprises a flange extending into the slot behind the facesheet, thefacesheet capturing the flange of the clip in the slot.
 15. The panelsystem of claim 11, wherein the clip comprises a base portion, the tabof the tab panel comprising a channel, the tab panel securing membercomprising a protrusion extending from the base portion and received inthe channel, the slot panel securing member comprising a deflectable tabextending from the base portion deflectable between an unlatchedposition and a latched position, the deflectable tab being deflected tothe unlatched position as the clip is loaded into the slot, thedeflectable tab being deflected to the latched position after thedeflectable tab clears the facesheet of the slot panel, the deflectabletab engaging an interior surface of the facesheet of the slot panel inthe latched position.
 16. The panel system of claim 11, wherein the tabof the tab panel includes a channel, the clip being secured in thechannel of the tab prior to loading the tab into the slot.
 17. The panelsystem of claim 11, wherein the facesheet of the slot panel has an edgearound a perimeter of the slot, the slot panel includes an interiorsurface and an exterior surface, the slot panel securing member issecured against the interior surface adjacent the edge.
 18. The panelsystem of claim 11, wherein the core of the tab panel is a honeycombcore having a honeycomb structure and wherein the core of the slot panelis a honeycomb core having a honeycomb structure.
 19. The panel systemof claim 11, wherein the core of the tab panel is a foam material andwherein the core of the slot panel is a foam material.
 20. A panelsystem kit comprising: a plurality of panels each having a core betweenopposite facesheets, each of the panels configured to have at least oneof a slot or a tab; and a plurality of clips configured to be positionedbetween corresponding panels to join the panels, each clip having a slotpanel securing member configured to securely engage an interior surfaceof a corresponding facesheet of the panel having the slot, each cliphaving a tab panel securing member configured to securely engage acorresponding facesheet of the panel having the tab, wherein the clipsare received in channels in corresponding tabs and loaded intocorresponding slots with the corresponding tabs; wherein the clip isconfigured to be received in the corresponding slot formed in thecorresponding panel such that the slot panel securing member extendsinto the slot behind the facesheet and the facesheet captures the slotpanel securing member in the slot.
 21. The panel system kit of claim 20,wherein each of the clips have a base portion configured to be receivedin a corresponding slot in one of the panels.
 22. The panel system kitof claim 20, wherein the tab panel securing member is configured tosnapably engage the corresponding panel and the slot panel securingmember is configured to snapably engage the corresponding panel.
 23. Thepanel system kit of claim 20, wherein the slot panel securing member isconfigured to be positioned between the facesheet and the core of thecorresponding panel.
 24. The panel system kit of claim 20, wherein eachof the clips has a base portion defining a pocket configured to receivea portion of the corresponding tab of the corresponding panel.
 25. Thepanel system kit of claim 20, wherein each of the clips have a baseportion, the tab panel securing member comprises a protrusion extendingfrom the base portion and received in a channel in the correspondingpanel having the tab, the slot panel securing member comprising adeflectable tab extending from the base portion deflectable between anunlatched position and a latched position, the deflectable tab beingdeflectable to the unlatched position as the clip is loaded into theslot, the deflectable tab being deflectable to the latched positionafter the deflectable tab clears the facesheet of the correspondingpanel having the slot, the deflectable tab engaging an interior surfaceof the facesheet of the corresponding panel having the slot in thelatched position.
 26. A method of assembling a panel system, the panelsystem including a tab panel having at least one tab extending therefromand a slot panel having at least one slot receiving the correspondingtab of the tab panel, the tab panel and slot panel each having a coreand a facesheet adjacent the core, the panel system further including aclip having a tab panel securing member and a slot panel securingmember, the method comprising: inserting the clip onto the tab paneladjacent the tab; inserting the tab panel securing member in a channelformed in the tab panel to securely couple the clip to the tab panel;inserting the tab and the previously inserted clip in the slot such thatthe clip is positioned between a portion of the tab panel and a portionof the slot panel; and inserting the slot panel securing member betweenthe facesheet of the slot panel and the core of the slot panel such thatthe slot panel securing member engages an interior surface of thefacesheet to secure the slot panel securing member to the slot panel.27. The method of claim 26, wherein said inserting the tab in the slotcomprises pressing the slot panel securing member outward such that theslot panel securing member is captured behind the facesheet of the slotpanel.
 28. The method of claim 26, wherein said inserting the slot panelsecuring member between the facesheet of the slot panel and the core ofthe slot panel comprises snapably loading the clip into the slot of theslot panel such that the slot panel securing member is captured behindthe facesheet of the slot panel.
 29. The panel system kit of claim 20,wherein the tab panel includes at least one slot and the slot panelincludes at least one tab with a corresponding clip therebetween.